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US5433898A - Method of manufacturing a contact lens - Google Patents

Method of manufacturing a contact lens Download PDF

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Publication number
US5433898A
US5433898A US07/944,891 US94489192A US5433898A US 5433898 A US5433898 A US 5433898A US 94489192 A US94489192 A US 94489192A US 5433898 A US5433898 A US 5433898A
Authority
US
United States
Prior art keywords
end wall
contact lens
casting mould
manufacturing
monomer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US07/944,891
Other languages
English (en)
Inventor
Ashok R. Thakrar
Khushroo Gandhi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Novartis AG
Original Assignee
PBH Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by PBH Inc filed Critical PBH Inc
Priority to US07/944,891 priority Critical patent/US5433898A/en
Assigned to PILKINTGTON, VISIONCARE, INC. reassignment PILKINTGTON, VISIONCARE, INC. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: GANDHI, KHUSHROO, THAKRAR, ASHOK R.
Priority to AU51025/93A priority patent/AU675248B2/en
Priority to AT93920498T priority patent/ATE225706T1/de
Priority to JP50814994A priority patent/JP3309856B2/ja
Priority to PCT/US1993/008455 priority patent/WO1994006621A1/en
Priority to CA002144165A priority patent/CA2144165C/en
Priority to IL106978A priority patent/IL106978A0/xx
Priority to DE69332383T priority patent/DE69332383T2/de
Priority to ZA936703A priority patent/ZA936703B/xx
Priority to EP93920498A priority patent/EP0670770B1/de
Priority to MX9305590A priority patent/MX9305590A/es
Priority to CN93116835A priority patent/CN1085843A/zh
Assigned to PILKINGTON BARNES HIND, INC. reassignment PILKINGTON BARNES HIND, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PILKINGTON VISIONCARE, INC.
Publication of US5433898A publication Critical patent/US5433898A/en
Application granted granted Critical
Assigned to BANKERS TRUST COMPANY reassignment BANKERS TRUST COMPANY GRANT OF SECURITY INTEREST Assignors: PBH, INC.
Assigned to BANKERS TRUST COMPANY reassignment BANKERS TRUST COMPANY SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PBH INC.
Assigned to PBH, INC. reassignment PBH, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: PILKINGTON BARNES HIND, INC.
Assigned to PBH, INC. reassignment PBH, INC. RELEASE OF A SECURITY INTEREST Assignors: BANKERS TRUST COMPANY
Assigned to NOVARTIS AG reassignment NOVARTIS AG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: PBH, INC.
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/021—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles by casting in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00028—Bifocal lenses; Multifocal lenses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00038—Production of contact lenses
    • B29D11/00048—Production of contact lenses composed of parts with dissimilar composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D11/00—Producing optical elements, e.g. lenses or prisms
    • B29D11/00009—Production of simple or compound lenses
    • B29D11/00317—Production of lenses with markings or patterns
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04—Contact lenses for the eyes
    • G02C7/041—Contact lenses for the eyes bifocal; multifocal
    • G02C7/044—Annular configuration, e.g. pupil tuned
    • G—PHYSICS
    • G02—OPTICS
    • G02C—SPECTACLES; SUNGLASSES OR GOGGLES INSOFAR AS THEY HAVE THE SAME FEATURES AS SPECTACLES; CONTACT LENSES
    • G02C7/00—Optical parts
    • G02C7/02—Lenses; Lens systems ; Methods of designing lenses
    • G02C7/04—Contact lenses for the eyes
    • G02C7/049—Contact lenses having special fitting or structural features achieved by special materials or material structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers

Definitions

  • This invention relates to a method of manufacturing a contact lens, and, in particular, to a method of manufacturing a contact lens from two or more differing materials, for example a composite lens, bifocal or trifocal lens.
  • Normally contact lenses when formed from two or more materials are formed with a first member formed from a first material, and a second member formed from a second material.
  • a composite lens which is generically known as "Saturn” in the industry wherein the first member comprises the optical zone of the lenses and is normally made from a "hard” material such as a rigid gas permeable (RGP) material, and the second member comprises a skirt around the optical zone and is normally made from a "soft” material, such as a hydrogel material.
  • RGP rigid gas permeable
  • the actual diameter of the first rod of material provides the dimensions of a significant characteristic of the finished lens. Therefore the first rod of material has to have a uniform diameter
  • the adhesion between the two materials of the two members as a result of the different character of the materials of the composite lens may be very low, and when this is combined with the fact that the soft contact lens material will be swollen after manufacture and prior to use exerting a considerable force on this adhesion the problems can be significant.
  • the present invention is concerned with providing a method of manufacturing contact lenses for example composite contact lenses of multifocal contact lenses in which the above discussed problems have at least been alleviated of reduced significantly.
  • a method of manufacturing a contact lens which has a first section formed from a first material, and a second section formed from a second material
  • a casting mould of generally cylindrical construction and having a side wall and an end wall, which end wall has an inward displacement into the space defined by the side wall, which space defined by the side wall and end wall is a receptive well into which material can be cast to be cured/polymerised, which method comprises
  • the first monomer material includes a polymerisable material which has a penetrating like action with respect to the material from which the end wall of the casting mould is formed.
  • the casting moulds for use in the method of manufacture of the present invention can be mass produced from suitable contact lens materials relatively cheaply and with a high degree of accuracy.
  • the moulds may be produced by moulding of the material in a polystyrene mould.
  • the polystyrene mould itself being injection moulded at a very low cost.
  • the inward displacement of the end wall of the casting mould is a solid projection the material of which forms one of the sections of the contact lens.
  • a method of manufacturing a contact lens which has a first section formed from a first material, and a second section formed from a second material includes the use of a casting mould of cylindrical construction and having a side wall and an end wall, which end wall has an inward displacement into a space defined by the side wall so that the casting mould has two receptive wells for the casting of material to be cured/polymerised which are separated from one another by the end wall of the casting mould, which method comprises:
  • first and second monomer materials include a polymerisable material which has a penetrating like action with respect to the material from which the end wall of the casting mould is formed.
  • first and second monomer materials of a polymerisable material with a penetrating like action with respect to the material of the end wall of the casting mould means that the polymerisable material softens, swells and/or dissolves the surface material of the end wall of the casting mould and upon polymerisation a very strong bonded interface is produced between the monomer material cast and the end wall of the casting mould.
  • bond strength of a button made in accordance with the present invention is significantly increased over that which would be present should the two materials have been placed in direct contact bonding.
  • a button which includes the end wall of the casting mould sandwiched between the two bodies of polymerised first and second monomer material, each of the bodies of polymerised first and second monomer material being strongly bonded to the respective surface of the end wall of the casting mould as discussed in the paragraph above.
  • the incorporation of the casting mould, or a part thereof, into the button means that the method in accordance with the present invention utilises a simple one or two stage cast moulding operation which is significantly cheaper to operate than the presently used method.
  • the casting mould is formed with a side wall and end wall that are formed from the same material, so a strong interface is also formed between the cast material and the side wall.
  • the end wall has an inward displacement into the space defined by the side wall of the casting mould which inward displacement is conical in shape.
  • the cone so formed as the inward displacement may have a base area which is any proportion of the area of the end wall of the mould up to 100%. Further the cone may be located with its apex at the, or in line with the, centre of the end wall or off centre therefrom.
  • the inward displacement in the end wall of the mould may comprise an upstanding cylinder.
  • the upstanding cylinder may be of any suitable cross-sectional shape, for example, circular, oval, semi-circular or polygonal.
  • one receptive well which is defined by the side wall and the end wall.
  • the end wall of the casting mould at least, is formed from polymethylmethacrylate and the polymerisable material with a penetrating like action of the first and second monomer materials is methylmethacrylate.
  • vinyl polymers and their monomers are useable in the present invention, for example, styrene, N-vinyl pyrrolidone (NVP), hydroxyethylmethacrylate (HEMA), dimethyl acrylamide (DMA), ethyleneglycoldimethacrylate (EGDMA), glyceral methacrylate (GMA).
  • NRP N-vinyl pyrrolidone
  • HEMA hydroxyethylmethacrylate
  • DMA dimethyl acrylamide
  • EGDMA ethyleneglycoldimethacrylate
  • GMA glyceral methacrylate
  • the end wall of the casting mould at least, is formed from cellulose acetate butyrate (Eastman Kodak TENITE M6 350A), resin and plasticiser, with the polymerisable material with the penetrating like action of the first and second monomer materials being a liquid vinyl monomer such as methyl methacrylate.
  • cellulose acetate butyrate Eastman Kodak TENITE M6 350A
  • resin and plasticiser with the polymerisable material with the penetrating like action of the first and second monomer materials being a liquid vinyl monomer such as methyl methacrylate.
  • the end wall of the casting mould is formed from polystyrene with the polymerisable material with penetrating like action of the first and second monomer materials being a liquid vinyl monomer such as N-vinyl pyrrolidone.
  • the end walls of the casting moulds are coloured.
  • the colouring of the casting mould end wall means that when the finished lens has been cut/turned from the moulded bottom, the material of the first member and the second will be divided by a coloured ring like zone.
  • the colouring of the casting mould can be used to provide in the finished contact lens a lens locating tint which can be introduced into the finished lens without any inconvenience to the lens wearer, and little additional cost, whilst providing the advantages associated with locater tints.
  • the colouring of the casting mould in the fashion disclosed can be used to provide a ring of distinct colour where required.
  • the casting mould has distinct cast moulding areas i.e., one or more receptive wells, and a mould each of the distinct zones of the finished contact lens can be coloured or not separately to provide an adaptable method of manufacturing contact lens.
  • the casting moulds for use with the method of the present invention are obviously formed with sufficient thickness of material to provide the strength necessary to ensure that no deformation is experienced during the casting of the monomer materials, and subsequent curing/polymerisation thereof.
  • the end wall of the casting mould should not be of such thickness that it begins to interfere with the optical properties of the finished contact lens.
  • the end wall of the casting mould has a thickness in the region of 0.1 mm to 2 mm.
  • the casting mould for use therewith has an end wall which is of a fairly uniform thickness, with respect to the side wall of the casting mould.
  • the thickness of the end wall will vary across said end wall.
  • the variation in thickness of the end wall may occur up the sides of the cone to its apex.
  • the inward displacement is an upstanding cylinder which forms a second receptive well for containing a suitable material and polymerisation thereof the variation in thickness of the end wall may occur around the side(s) of the upstanding cylinder.
  • the present invention may be used to manufacture contact lenses from any combination of materials of types of materials, for example hard and hard, hard and soft, and soft and soft.
  • hard contact lens material is well known in the industry and within the general terms there is included a large variety of materials. Most preferably, the hard contact lens material is a rigid gas permeable material, such as Fluorocon.
  • soft contact lens material is well known in the industry, and is the general term used in respect of hydrogel materials, that is materials which can be readily hydrolised/swollen under the action of water. Typically these materials are very soft and flexible in nature once hydrolysed.
  • the "soft contact lens material” may be a silicone.
  • the soft contact lens material is a hydrogel, such as that disclosed in co-pending application No. 641273.
  • FIG. 1 shows a side view cross section of a casting mould for use in a method of manufacturing a contact lens in accordance with the present invention
  • FIGS. 2 to 4 show schematic representations of a method in accordance with the present invention
  • FIG. 5 shows a schematic side view cross section of a contact lens made in accordance with the present invention
  • FIG. 6 shows a schematic plan view of the contact lens shown in FIG. 5 of the accompanying drawings.
  • FIG. 7A is a sectional view of a cast button for making a contact lens according to a second embodiment of the present invention.
  • FIG. 7B is a plan view of a lens made from the cast button of FIG. 7A;
  • FIG. 7C is a side view of the lens shown in FIG. 7B;
  • FIG. 8A is a sectional view of a cast button for making a contact lens according to a third embodiment of the present invention.
  • FIG. 8B is a plan view of a lens made from the cast button of FIG. 8A;
  • FIG. 8C is a side view of the lens shown in FIG. 8B;
  • FIG. 9A is a sectional view of a cast button for making a contact lens according to a fourth embodiment according to the present invention.
  • FIG. 9B is a plan view of a lens made from the cast button of FIG. 9A;
  • FIG. 9C is a side view of the lens shown in FIG. 9B;
  • FIG. 10A is a sectional view of a cast button for making a contact lens according to a fifth embodiment according to the present invention.
  • FIG. 10B is a plan view of a lens made from the cast button of FIG. 10A;
  • FIG. 10C is a side view of the lens shown in FIG. 10B;
  • FIG. 11A is a sectional view of a cast button for making a contact lens according to a sixth embodiment according to the present invention.
  • FIG. 11B is a plan view of a lens made from the cast button of FIG. 11A;
  • FIG. 11C is a side view of the lens shown in FIG. 11B;
  • FIG. 12A is a sectional view of a cast button for making a contact lens according to a seventh embodiment according to the present invention.
  • FIG. 12B is a plan view of a lens made from the cast button of FIG. 12A.
  • FIG. 12C is a side view of the lens shown in FIG. 12B;
  • FIG. 1 of the accompanying drawings there is shown a casting mould 1 for use in a method of manufacturing a contact lens in accordance with the present invention.
  • the casting mould 1 is of cylindrical construction having a side wall 2 and an end wall 3.
  • the end wall 3 is inwardly displaced into the space defined within the side wall 2, and is of conical construction.
  • the casting mould 1 defines two receptive wells for holding liquid material.
  • the first of these wells A is defined by surface 4 of the end wall 3, and is external of the cylindrical side wall 2 of the casting mould 1.
  • the second of the receptive wells B is defined by surface 5 of the end wall 3 and the cylindrical side wall 2 of the casting mould 1.
  • the wells A and B are located on opposite sides of the end wall 3.
  • the end wall 3 of the casting mould has a thickness of 1.0 mm.
  • FIGS. 2 to 6 of the accompanying drawings a method of manufacturing a contact lens in accordance with the present invention will now be described.
  • the casting mould 1 is located so that the receptive well A thereof is capable of holding liquid monomeric material.
  • the liquid monomeric material of a first material is poured into the receptive well A and polymerised.
  • the receptive well A is filled with a hardened mass of polymeric material which is retained in place by the interaction of the cast monomeric material with the material of the end wall 3.
  • the mould is now reversed and the receptive well B filled with liquid monomer of a second material which is then polymerised.
  • a first optical surface 6 is machined onto the button as shown in FIG. 4.
  • the button is reversed and the second optical surface 7 is machined thereon.
  • This contact lens comprises:
  • the material of the skirt 8 can then be hydrolysed/and swollen to provide the material with its soft and pliable nature. This is done in accordance with the well known procedures currently used in the industry.
  • the actual diameter of the central area 9 formed in the contact lens, because of the conical nature of the receptive well A of the casting mould 1 is dependent upon the depth of cut used to form the contact lens from the button. Therefore by adjusting the depth of cut used to form the contact lens from the button the size of the central area 9 can be adjusted to the wearer's requirements and the lighting background in the area he lives.
  • a contact lens as described above is formed by the above method as follows using a casting mould 1 which is formed with an end wall that is made from polymethyl methacrylate (PMMA).
  • PMMA polymethyl methacrylate
  • the central area 9 (formed from the monomer material cast into receptive well A of the casting mould 1) is formed from a monomer mixture with the following composition:
  • the skirt 8 (formed from the monomer material cast into receptive well B of the casting mould 1) is formed from a monomer mixture with the following composition:
  • the contact lens is then cut with the central area 9 having a diameter of 9.00 mm and the skirt 8 having a diameter of 14.00 mm.
  • FIG. 7A of the accompanying drawings which shows a cast moulded button B, and a cross-sectional view and plan view of a contact lens manufactured from the button B.
  • the button B is cast moulded with a casting mould 20 which is incorporated into the finished button B.
  • the casting mould 20 is manufactured from polymethylmethacrylate and is of generally circular configuration having a side wall 21 and a base wall 22.
  • the base wall 22 of the casting mould is inwardly displaced in the shape of a regular cone into the space surrounded by the side wall 21, with the apex of the cone in line with the central axis of the side wall 21.
  • the material cast into the space S is a hydrogel material which is of the following composition
  • the outline CL in the button shows the position of a contact lens which is to be machined from the button.
  • FIG. 7B a cross sectional view and a plan view of a contact lens so machined from the button.
  • the lens has an outer member 23 and an inner member 24, these members are separated from one another by the moulding cast 20.
  • FIGS. 8A and 8B of the accompanying drawings there is shown in FIG. 8A another cast moulded button B and in FIG. 8b a cross-sectional view and a plan view of a contact lens manufactured from the button B.
  • this button B and the contact lens CL formed therefrom are very similar to that discussed with reference to FIGS. 7A and 7B and consequently like numerals have been used to indicate like components.
  • the inward displacement in the base wall is again conical in shape, however is slightly offset from the axis which runs through the casting mould case 20.
  • the net result of this can be clearly seen from the plan view of the contact lens, illustrated in FIG. 8B in that the first member is elliptical in shape, and not circular as in the example discussed with respect to FIGS. 7A and 7B of the accompanying drawings.
  • buttons B and the contact lens CL formed therefrom are formed from the same materials as discussed with regard to FIGS. 7A and 7B of the accompanying drawings.
  • FIGS. 9A and 9B of the accompanying drawings in which there is shown another form of cast button B, with cross-sectional view and plan view of a contact lens manufactured therefrom.
  • the inward displacement in the base wall 22 is cylindrical in shape, the central axis of the displacement being offset from the central axis of the moulding cast.
  • the first member is elliptical in shape, and not circular.
  • buttons B and the contact lens CL formed therefrom are formed from the same materials as discussed with regard to FIGS. 7A and 7B of the accompanying drawings.
  • FIGS. 10A and 10B of the accompanying drawings in which another form of cast button B, and contact lens manufactured therefrom are shown.
  • the differences are in the contraction of the casting mould 20 in the vicinity of the base.
  • the casting mould 20 has been made so that the side wall 21 and the base wall 22 are of equivalent thickness.
  • the base wall 22 is of much greater thickness than the side wall 21.
  • the net effect of this is clearly shown in the plan view of the contact lens machined from the button B, where the barrier between the first and second members of the contact lens provided by the casting mould 20 is much thicker than with the previous examples.
  • a concentric bifocal lens is prepared.
  • buttons B and the contact lens CL formed therefrom are formed with the same materials as discussed with regard to FIGS. 7A and 7B of the accompanying drawings.
  • FIGS. 11A and 11B of the accompanying drawings there is shown another form of cast button B, and cross-sectional view and plan view of a contact lens manufactured therefrom.
  • a casting mould 30 is manufactured from polystyrene, and comprises a cylindrical side wall 31 with a base wall 32.
  • the base wall 32 has an upstanding solid post member 33 which has an axis slightly offset kept parallel to the equivalent axis of the casting mould as a whole.
  • the casting mould 30 in this case may be manufactured by injection moulding into this particular fashion or, alternatively, a casting mould similar to that shown in FIGS. 9A and 9B of the accompanying drawings may be used with the space T having polymer identical to that from which the casting mould 30 is made, cast and polymerised therein.
  • the casting mould only defines one receptive well for the casting of material to form the button.
  • polymeric material of the following composition is cast into the receptive well.
  • the cast button B may be machined to form a contact lens which has a first member 34 formed from the material of the upstanding post of the casting mould and a second member formed from the material cast into the receptive well of the mould.
  • FIGS. 12A and 12B of the accompanying drawings a seventh basic design of cast button B and contact lens CL formed therefrom is shown.
  • the cast button B is formed using a casting mould 41 which is incorporated into the cast button B.
  • the casting mould 41 in this case is manufactured from an optically clear material, such as polystyrene.
  • the mould 41 includes;
  • first side wall 44 which circumferentially surrounds the periphery of the end wall 42 and is connected thereto;
  • a second side wall 43 which is connected to the end wall 42 within the space defined by the first side wall 44 and is upstanding therefore.
  • a casting mould 41 of this fashion defines two receptive wells 45 and 46 into which polymeric monomer material can be cast in order to enable the forming of a cast button B, one of which receptive wells 46 is circumferentially surrounded by the other receptive well 45.
  • the receptive well 45 is defined by the inner surfaces of the first side wall 44 and the end wall 42 and the outer surface of the second side wall 43.
  • the receptive well 46 is defined by the inner surfaces of the second side wall 43 and the end wall 42.
  • the second side wall 43 constitutes an inward displacement of the end wall 42.
  • Both of the wells 45, 46 are located on the same side of the end wall 42.
  • liquid monomeric material is cast into the receptive wells 45 and 46 and polymerised.
  • the method of casting a button using this casting mould 41 may be identical with that disclosed above for the formation of the casting button.
  • the receptive wells 45 and 46 are disposed on the same side so the liquid monomer material may be cast into the appropriate receptive well and polymerised/cured simultaneously. That is to say the first polymerising/curing step of the earlier detailed method has been leftout.
  • liquid monomeric material cast into receptive well 45 comprises
  • liquid monomeric material cast into receptive well 46 comprises

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Ophthalmology & Optometry (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Eyeglasses (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
US07/944,891 1992-09-11 1992-09-11 Method of manufacturing a contact lens Expired - Lifetime US5433898A (en)

Priority Applications (12)

Application Number Priority Date Filing Date Title
US07/944,891 US5433898A (en) 1992-09-11 1992-09-11 Method of manufacturing a contact lens
AU51025/93A AU675248B2 (en) 1992-09-11 1993-09-09 A method of manufacturing a contact lens
MX9305590A MX9305590A (es) 1992-09-11 1993-09-10 Un metodo para fabricar un lente de contacto.
JP50814994A JP3309856B2 (ja) 1992-09-11 1993-09-10 コンタクトレンズの製造方法
PCT/US1993/008455 WO1994006621A1 (en) 1992-09-11 1993-09-10 A method of manufacturing a contact lens
CA002144165A CA2144165C (en) 1992-09-11 1993-09-10 A method of manufacturing a contact lens
IL106978A IL106978A0 (en) 1992-09-11 1993-09-10 Manufacture of a contact lens
DE69332383T DE69332383T2 (de) 1992-09-11 1993-09-10 Verfahren zur herstellung einer kontaktlinse
ZA936703A ZA936703B (en) 1992-09-11 1993-09-10 A method of manufacturing a contact lens
EP93920498A EP0670770B1 (de) 1992-09-11 1993-09-10 Verfahren zur herstellung einer kontaktlinse
AT93920498T ATE225706T1 (de) 1992-09-11 1993-09-10 Verfahren zur herstellung einer kontaktlinse
CN93116835A CN1085843A (zh) 1992-09-11 1993-09-11 制造隐形眼镜的方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US07/944,891 US5433898A (en) 1992-09-11 1992-09-11 Method of manufacturing a contact lens

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US5433898A true US5433898A (en) 1995-07-18

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US07/944,891 Expired - Lifetime US5433898A (en) 1992-09-11 1992-09-11 Method of manufacturing a contact lens

Country Status (12)

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US (1) US5433898A (de)
EP (1) EP0670770B1 (de)
JP (1) JP3309856B2 (de)
CN (1) CN1085843A (de)
AT (1) ATE225706T1 (de)
AU (1) AU675248B2 (de)
CA (1) CA2144165C (de)
DE (1) DE69332383T2 (de)
IL (1) IL106978A0 (de)
MX (1) MX9305590A (de)
WO (1) WO1994006621A1 (de)
ZA (1) ZA936703B (de)

Cited By (35)

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US6010647A (en) * 1997-06-30 2000-01-04 Fuji Photo Optical Co., Ltd. Multifocal lens and method of making the same
US6054034A (en) * 1990-02-28 2000-04-25 Aclara Biosciences, Inc. Acrylic microchannels and their use in electrophoretic applications
US6176962B1 (en) 1990-02-28 2001-01-23 Aclara Biosciences, Inc. Methods for fabricating enclosed microchannel structures
US6217171B1 (en) 1998-05-26 2001-04-17 Novartis Ag Composite ophthamic lens
US20040046931A1 (en) * 2002-09-06 2004-03-11 Jerome Legerton Hybrid contact lens system and method
US20040099971A1 (en) * 2002-11-25 2004-05-27 Technology Resource International Corporation Lens molds and method of using the same
US20040179167A1 (en) * 2002-09-06 2004-09-16 Ali Dahi Hybrid contact lens system and method
US20040212779A1 (en) * 2002-09-06 2004-10-28 Ali Dahi Hybrid contact lens system and method
US20050018130A1 (en) * 2002-09-06 2005-01-27 Ali Dahi Hybrid contact lens system and method
US7018039B2 (en) 2003-11-14 2006-03-28 Synergeyes,Inc. Contact lens
US20060250576A1 (en) * 2005-05-06 2006-11-09 Legerton Jerome A Hybrid contact lens system and method of fitting
US20070082563A1 (en) * 2005-10-11 2007-04-12 Jerome Legerton Hybrid contact lens system and method of fitting
US20070273825A1 (en) * 2006-05-25 2007-11-29 Jerome Legerton Hybrid contact lens system and method of fitting
US20080074611A1 (en) * 2006-09-22 2008-03-27 Meyers William E Hybrid contact lens with improved resistance to flexure and method for designing the same
US20080291392A1 (en) * 2007-04-12 2008-11-27 Sicari Joseph E System and method for marking an ophthalmic lens
US20090166507A1 (en) * 2007-12-31 2009-07-02 Bruce Lawton Casting Mold for Forming a Biomedical Device including an Ophthalmic Device
US7828432B2 (en) 2007-05-25 2010-11-09 Synergeyes, Inc. Hybrid contact lenses prepared with expansion controlled polymeric materials
CN101076752B (zh) * 2004-12-27 2012-02-29 Hoya株式会社 复合隐形眼镜以及透镜材料的制造方法
EP2564264A1 (de) 2010-04-13 2013-03-06 Johnson & Johnson Vision Care, Inc. Kontaktlinsen mit verringerter innenblendung
US8459793B2 (en) 2009-10-23 2013-06-11 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US8591025B1 (en) 2012-09-11 2013-11-26 Nexisvision, Inc. Eye covering and refractive correction methods for LASIK and other applications
US8678584B2 (en) 2012-04-20 2014-03-25 Nexisvision, Inc. Contact lenses for refractive correction
US8864306B2 (en) 2011-04-28 2014-10-21 Nexisvision, Inc. Eye covering and refractive correction methods and apparatus having improved tear flow, comfort, and/or applicability
US9341864B2 (en) 2013-11-15 2016-05-17 Nexisvision, Inc. Contact lenses having a reinforcing scaffold
US9395558B2 (en) 2010-10-25 2016-07-19 Nexisvision, Inc. Methods and apparatus to identify eye coverings for vision
US9423632B2 (en) 2012-04-20 2016-08-23 Nexisvision, Inc. Contact lenses for refractive correction
US9465233B2 (en) 2012-04-20 2016-10-11 Nexisvision, Inc. Bimodular contact lenses
US9740026B2 (en) 2013-06-26 2017-08-22 Nexisvision, Inc. Contact lenses for refractive correction
US9943401B2 (en) 2008-04-04 2018-04-17 Eugene de Juan, Jr. Therapeutic device for pain management and vision
US10191303B2 (en) 2014-01-29 2019-01-29 Nexisvision, Inc. Multifocal bimodulus contact lenses
US10596038B2 (en) 2009-10-23 2020-03-24 Journey1, Inc. Corneal denervation for treatment of ocular pain
US10816822B2 (en) 2010-04-13 2020-10-27 Johnson & Johnson Vision Care, Inc. Pupil-only photochromic contact lenses displaying desirable optics and comfort
US10894374B2 (en) 2010-04-13 2021-01-19 Johnson & Johnson Vision Care, Inc. Process for manufacture of a thermochromic contact lens material
US11724471B2 (en) 2019-03-28 2023-08-15 Johnson & Johnson Vision Care, Inc. Methods for the manufacture of photoabsorbing contact lenses and photoabsorbing contact lenses produced thereby
US12044905B2 (en) 2011-04-28 2024-07-23 Journey1 Inc Contact lenses for refractive correction

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US5923397A (en) * 1996-03-25 1999-07-13 Bausch & Lomb Incorporated Bimodulus contact lens article
JP2002501626A (ja) * 1997-05-27 2002-01-15 ノバルティス アクチエンゲゼルシャフト 複合眼用レンズ
EP1750157B1 (de) * 2004-05-28 2010-10-13 Menicon Co., Ltd. Kontaktlinse
JP5775817B2 (ja) * 2009-07-08 2015-09-09 株式会社メニコン ハイブリッドソフトコンタクトレンズ、この製造方法及び水和処理方法
FR2956752B1 (fr) * 2010-02-25 2012-07-27 Lentilles Procede de fabrication d'une lentille de contact hybride
DE102010047846B4 (de) * 2010-09-30 2017-11-09 Carl Zeiss Vision International Gmbh Optische Linse und Verfahren zum Herstellen einer optischen Linse
FR2979072B1 (fr) 2011-08-16 2013-09-27 Lentilles Procede, dispositif et piece composite pour la fabrication d'une lentille hybride
US9180610B2 (en) * 2012-08-23 2015-11-10 Crt Technology, Inc. Devices and processes for fabricating multi-component optical systems

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US4197266A (en) * 1974-05-06 1980-04-08 Bausch & Lomb Incorporated Method for forming optical lenses
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Cited By (68)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6054034A (en) * 1990-02-28 2000-04-25 Aclara Biosciences, Inc. Acrylic microchannels and their use in electrophoretic applications
US6176962B1 (en) 1990-02-28 2001-01-23 Aclara Biosciences, Inc. Methods for fabricating enclosed microchannel structures
US6010647A (en) * 1997-06-30 2000-01-04 Fuji Photo Optical Co., Ltd. Multifocal lens and method of making the same
US6217171B1 (en) 1998-05-26 2001-04-17 Novartis Ag Composite ophthamic lens
US6579918B1 (en) 1998-05-26 2003-06-17 Novartis Ag Composite ophthalmic lens
US7163292B2 (en) 2002-09-06 2007-01-16 Synergeyes, Inc. Hybrid contact lens system and method
US7585074B2 (en) 2002-09-06 2009-09-08 Synergeyes, Inc. Hybrid contact lens system and method
US20040179167A1 (en) * 2002-09-06 2004-09-16 Ali Dahi Hybrid contact lens system and method
US20040212779A1 (en) * 2002-09-06 2004-10-28 Ali Dahi Hybrid contact lens system and method
US20050018130A1 (en) * 2002-09-06 2005-01-27 Ali Dahi Hybrid contact lens system and method
US20040046931A1 (en) * 2002-09-06 2004-03-11 Jerome Legerton Hybrid contact lens system and method
US7097301B2 (en) 2002-09-06 2006-08-29 Synergeyes, Inc. Hybrid contact lens system and method
US7104648B2 (en) 2002-09-06 2006-09-12 Synergeyes, Inc. Hybrid contact lens system and method
US7322694B2 (en) 2002-09-06 2008-01-29 Synergeyes, Inc. Hybrid contact lens system and method
US20060256284A1 (en) * 2002-09-06 2006-11-16 Ali Dahi Hybrid contact lens system and method
US20060285072A1 (en) * 2002-09-06 2006-12-21 Ali Dahi Hybrid contact lens system and method
US20040099971A1 (en) * 2002-11-25 2004-05-27 Technology Resource International Corporation Lens molds and method of using the same
US20070273834A1 (en) * 2003-11-14 2007-11-29 Jerome Legerton Contact Lens
US7018039B2 (en) 2003-11-14 2006-03-28 Synergeyes,Inc. Contact lens
KR101250597B1 (ko) * 2004-12-27 2013-04-03 호야 가부시키가이샤 복합 콘택트 렌즈 및 렌즈의 제조 방법
CN101076752B (zh) * 2004-12-27 2012-02-29 Hoya株式会社 复合隐形眼镜以及透镜材料的制造方法
US7543936B2 (en) 2005-05-06 2009-06-09 Synergeyes, Inc. Hybrid contact lens system and method of fitting
US20060250576A1 (en) * 2005-05-06 2006-11-09 Legerton Jerome A Hybrid contact lens system and method of fitting
US20070082563A1 (en) * 2005-10-11 2007-04-12 Jerome Legerton Hybrid contact lens system and method of fitting
US7377637B2 (en) 2005-10-11 2008-05-27 Synergeyes, Inc. Hybrid contact lens system and method of fitting
US7537339B2 (en) 2006-05-25 2009-05-26 Synergeyes, Inc. Hybrid contact lens system and method of fitting
US20070273825A1 (en) * 2006-05-25 2007-11-29 Jerome Legerton Hybrid contact lens system and method of fitting
US20080074611A1 (en) * 2006-09-22 2008-03-27 Meyers William E Hybrid contact lens with improved resistance to flexure and method for designing the same
US20080291392A1 (en) * 2007-04-12 2008-11-27 Sicari Joseph E System and method for marking an ophthalmic lens
US7828432B2 (en) 2007-05-25 2010-11-09 Synergeyes, Inc. Hybrid contact lenses prepared with expansion controlled polymeric materials
US20090166507A1 (en) * 2007-12-31 2009-07-02 Bruce Lawton Casting Mold for Forming a Biomedical Device including an Ophthalmic Device
US7850878B2 (en) 2007-12-31 2010-12-14 Bausch & Lomb Incorporated Method of forming a biomedical device including an ophthalmic device
US8070475B2 (en) 2007-12-31 2011-12-06 Bausch & Lomb Incorporated Casting mold for forming a biomedical device including an ophthalmic device
US9943401B2 (en) 2008-04-04 2018-04-17 Eugene de Juan, Jr. Therapeutic device for pain management and vision
US10555804B2 (en) 2008-04-04 2020-02-11 Journey1, Inc. Therapeutic device for pain management and vision
US8459793B2 (en) 2009-10-23 2013-06-11 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US9498385B2 (en) 2009-10-23 2016-11-22 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US10627649B2 (en) 2009-10-23 2020-04-21 Journey1, Inc. Conformable therapeutic shield for vision and pain
US8926096B2 (en) 2009-10-23 2015-01-06 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US9107773B2 (en) 2009-10-23 2015-08-18 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US9241837B2 (en) 2009-10-23 2016-01-26 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US10663761B2 (en) 2009-10-23 2020-05-26 Journey1, Inc. Conformable therapeutic shield for vision and pain
US10596038B2 (en) 2009-10-23 2020-03-24 Journey1, Inc. Corneal denervation for treatment of ocular pain
US9810921B2 (en) 2009-10-23 2017-11-07 Nexisvision, Inc. Conformable therapeutic shield for vision and pain
US10894374B2 (en) 2010-04-13 2021-01-19 Johnson & Johnson Vision Care, Inc. Process for manufacture of a thermochromic contact lens material
US11724472B2 (en) 2010-04-13 2023-08-15 Johnson & Johnson Vision Care, Inc. Process for manufacture of a thermochromic contact lens material
US9690115B2 (en) 2010-04-13 2017-06-27 Johnson & Johnson Vision Care, Inc. Contact lenses displaying reduced indoor glare
US11391965B2 (en) 2010-04-13 2022-07-19 Johnson & Johnson Vision Care, Inc. Pupil-only photochromic contact lenses displaying desirable optics and comfort
US11789291B2 (en) 2010-04-13 2023-10-17 Johnson & Johnson Vision Care, Inc. Pupil-only photochromic contact lenses displaying desirable optics and comfort
US10816822B2 (en) 2010-04-13 2020-10-27 Johnson & Johnson Vision Care, Inc. Pupil-only photochromic contact lenses displaying desirable optics and comfort
EP2564264A1 (de) 2010-04-13 2013-03-06 Johnson & Johnson Vision Care, Inc. Kontaktlinsen mit verringerter innenblendung
US9395558B2 (en) 2010-10-25 2016-07-19 Nexisvision, Inc. Methods and apparatus to identify eye coverings for vision
US9740025B2 (en) 2011-04-28 2017-08-22 Nexisvision, Inc. Eye covering and refractive correction methods and apparatus having improved tear flow, comfort, and/or applicability
US11126011B2 (en) 2011-04-28 2021-09-21 Journey1, Inc. Contact lenses for refractive correction
US12044905B2 (en) 2011-04-28 2024-07-23 Journey1 Inc Contact lenses for refractive correction
US8864306B2 (en) 2011-04-28 2014-10-21 Nexisvision, Inc. Eye covering and refractive correction methods and apparatus having improved tear flow, comfort, and/or applicability
US9465233B2 (en) 2012-04-20 2016-10-11 Nexisvision, Inc. Bimodular contact lenses
US10036900B2 (en) 2012-04-20 2018-07-31 Nexisvision, Inc. Bimodular contact lenses
US8678584B2 (en) 2012-04-20 2014-03-25 Nexisvision, Inc. Contact lenses for refractive correction
US9423632B2 (en) 2012-04-20 2016-08-23 Nexisvision, Inc. Contact lenses for refractive correction
US10039671B2 (en) 2012-09-11 2018-08-07 Nexisvision, Inc. Eye covering and refractive correction methods for lasik and other applications
US8591025B1 (en) 2012-09-11 2013-11-26 Nexisvision, Inc. Eye covering and refractive correction methods for LASIK and other applications
US9740026B2 (en) 2013-06-26 2017-08-22 Nexisvision, Inc. Contact lenses for refractive correction
US9851586B2 (en) 2013-11-15 2017-12-26 Nexisvision, Inc. Contact lenses having a reinforcing scaffold
US9341864B2 (en) 2013-11-15 2016-05-17 Nexisvision, Inc. Contact lenses having a reinforcing scaffold
US10191303B2 (en) 2014-01-29 2019-01-29 Nexisvision, Inc. Multifocal bimodulus contact lenses
US11724471B2 (en) 2019-03-28 2023-08-15 Johnson & Johnson Vision Care, Inc. Methods for the manufacture of photoabsorbing contact lenses and photoabsorbing contact lenses produced thereby
US12128641B2 (en) 2019-03-28 2024-10-29 Johnson & Johnson Vision Care, Inc. Methods for the manufacture of photoabsorbing contact lenses and photoabsorbing contact lenses produced thereby

Also Published As

Publication number Publication date
AU675248B2 (en) 1997-01-30
CN1085843A (zh) 1994-04-27
EP0670770A1 (de) 1995-09-13
JPH08505095A (ja) 1996-06-04
CA2144165A1 (en) 1994-03-31
AU5102593A (en) 1994-04-12
JP3309856B2 (ja) 2002-07-29
MX9305590A (es) 1994-05-31
EP0670770A4 (de) 1997-08-20
DE69332383T2 (de) 2003-10-23
IL106978A0 (en) 1993-12-28
ATE225706T1 (de) 2002-10-15
DE69332383D1 (de) 2002-11-14
CA2144165C (en) 2005-01-04
ZA936703B (en) 1994-03-30
EP0670770B1 (de) 2002-10-09
WO1994006621A1 (en) 1994-03-31

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